Copper promoted iron/cobalt spinels and their preparation

ABSTRACT

Slurried, high surface area, Cu promoted Fe-Co spinels which are fully reduced/carburized provide exceptionally high activity and selectivity in the conversion of CO/H 2  to alpha-olefins, particularly when carbided in-situ in the reactor. These copper iron-cobalt catalysts maintain good activity and selectivity under low pressure reaction conditions.

Continuation-in-part Application of U.S. Ser. No. 561,190 filed Dec. 14,1983, now U.S. Pat. No. 4,518,707.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to high surface area, copper promoted iron-cobaltspinel Fischer-Tropsch catalysts, their preparation and use inFischer-Tropsch slurry processes for selectively producing high amountsof C₂ to C₂₀ alpha-olefin materials.

2. Brief Description of the Prior Art

Methods for preparing low molecular weight olefins by Fischer-Tropschprocesses using coprecipitated iron-based catalysts including cobalt ascocatalyst, are well-known in the art, as described, for example, inU.S. Pat. Nos. 2,850,515; 2,686,195; 2,662,090; and 2,735,862; AICHE1981 Summer Nat'l Meeting Preprint No. 408, "The Synthesis of LightHydrocarbons from CO and H₂ Mixtures over Selected Metal Catalysts" ACS173rd Symposium, Fuel Division, New Orleans, March 1977; J. Catalysis1981, No. 72(1), pp. 37-50; Adv. Chem. Sem. 1981, 194, 573-88; PhysicsReports (Section C of Physics Letters) 12 No. 5 (1974) pp. 335-374; UKPatent Application No. 2050859A; J. Catalysis 72, 95-110 (1981); GmelinsHandbuch der Anorganische Chemie 8, Auflage (1959), pp 88-96; and Chem.Ing. Tech. 49 (1977) No. 6, pp. 463-468.

It is further known that high levels of cobalt in coprecipitatediron-cobalt alloy catalysts produce enhanced selectivity to olefinicproducts under certain process conditions, as described in Stud, Surf.Catal. 7, Pt/A, pp. 432 (1981).

Although the above-described prior art describes catalysts and processesdisplaying good fixed bed olefin synthesis activity, what isparticularly desired are slurry catalysts which can preferably becompletely pretreated in situ in the slurry liquid to yield the reduced,carbided active catalysts in the process displaying the combination ofgood C₂ -C₂₀ olefin synthesis activity, low selectivity to methane,coupled with long-term activity maintenance which is essential for asuccessful commercial process. Particularly desired is where thecatalyst precursor is the metal oxide spinel of the final catalystcomposition.

It has been found that low surface area ironcobalt spinels having BETsurface areas below 5 m² /g are not readily pretreated in situ in aFischer-Tropsch slurry liquid under mild conditions to readily yieldactive catalysts for producing C₂ -C₂₀ olefins.

The preparation of high surface metal oxides is described in the Frencharticle, "C. R. Acad. Sc. Paris", p268 (28 May 1969) by P. Courte and B.Delmon. The article describes a process for producing high surface areametal oxides by evaporating to dryness aqueous solutions of thecorresponding glycolic acid, lactic acid, malic or tartaric acid metalsalts. One oxide that was prepared by their described method was CoFe₂O₄.

However, the above references do not describe or suggest the use ofcopper promoted single phase Fe:Co spinels having iron-cobalt atomicratios of 4:1 or above or suggest their applicability in conducting orcarrying out slurry-type Fischer-Tropsch processes.

SUMMARY OF THE INVENTION

The present invention relates to unsupported, copper promoted, highsurface area, iron-cobalt spinels, their preparation and use ascatalysts in Fischer-Tropsch hydrocarbon synthesis for selectivelyproducing high amounts of C₂ to C₂₀ alpha-olefin hydrocarbons. Thus, inone embodiment of this invention, the catalysts of this invention willbe used to synthesize hydrocarbons, including C₂ to C₂₀ alphaolefinhydrocarbons, by contacting said catalyst, at elevated temperature, witha gaseous feed mixture of H₂ and CO for a time sufficient to convert atleast a portion of said feed to said hydrocarbons. This reaction ispreferably conducted in a slurry reactor. In a preferred embodiment, thecatalyst will be further promoted with one or more alkali or alkalinemetals of Group IA and IIA. It is particularly preferred that theadditional promoter metal comprise a Group IA alkali metal, such aspotassium.

The high surface area iron-cobalt spinels can be prepared by a processof adding an alphahydroxy aliphatic carboxylic acid, e.g., glycolicacid, to an aqueous solution containing dissolved iron and cobalt saltsand subsequently evaporating the solution to dryness to yield anamorphous mixed metal precursor salt. The so-formed precursor salt willthen be calcined at elevated temperatures sufficient to decompose thesalt to the corresponding high surface area spinel. The unsupported,high surface area Fe-Co spinels prepared in this manner, possess surfaceareas (BET) in the range of about 100-200 m² /g (square meters pergram), which are significantly higher than corresponding Fe-Co spinelsprepared by conventional processes, e.g., 0.2-1.0 m² /g.

The copper and, if desired, additional promoter metal or metals willthen be added to the so-formed Fe-Co spinel by any means known to thoseskilled in the are such as incipient wetness impregnation or multipleimpregnation with one or more promoter metal salt solutions, etc. Thechoice being left to the convenience of the practitioner. After thepromoter metal or metals have been added to the Fe-Co spinel by surfacedeposition or impregnation, the catalyst compositions of this inventionmay be formed by either of the two methods. In one method, the Fe-Cospinel containing copper and, if desired, additional promoter metal,will be charged to the reactor where the catalyst composition will beformed in-situ by contacting with a mixture of H₂ and CO at atemperature sufficient to obtain a fully reduced and carbided orcarburized composition which is the catalyst of this invention. This maybe accomplished under Fischer-Tropsch reaction conditions.

In another, alternative method, the Fe-Co spinel containing copper and,if desired, additional promoter metal will be subjected to hightemperature, e.g., 300°-400° C., H₂ reduction to obtain a fully reducedalloy, followed by treatment with H₂ /CO at elevated temperature (i.e.,300°-400° C.) to convert the alloy to a fully carburized state.

The resulting copper promoted, high surface area reduced and carburizedor carbided catalysts provide unusually high activity, selectivity andactivity maintenance in the direct conversion of CO/H₂ to alpha-olefinsunder slurry reactor conditions. These catalysts have higher COconversion activity and greater selectivity to alpha-olefins thansimilar compositions which are not promoted with copper disclosed incopending Ser. Nos. 561,190, now U.S. Pat. No. 4,518,707, and 561,192,now U.S. Pat. No. 4,544,671, filed on Dec. 14, 1983. These catalysts areespecially useful in low pressure slurry reactor systems wherealpha-olefin residence times in the reaction zone can be minimized, andthe physical properties of the catalyst bed are conducive to use offinely divided powdered catalysts.

In accordance with this invention, there is provided a composition ofmatter comprising an unsupported, iron-cobalt spinel promoted withcopper and, if desired, one or more promoter metals of Group IA and IIA,said spinel exhibiting a single phase powder x-ray diffraction patternsubstantially isostructural with Fe₃ O₄, and possessing a BET surfacearea greater than 5 m² /g and an iron-cobalt atomic ratio of about 4 to1 or above. As a practical matter, in most cases the surface area willbe at least about 50 m² /g.

Further provided is a composition of matter comprising a copper promotediron-cobalt metallic alloy, being isostructural with metallicalpha-iron, as determined by X-ray diffractometry, and possessing a BETsurface area greater than 5 m² /g, said alloy being produced bycontacting the above, described Fe:Co spinel with a reducing atmosphere.

Also provided is a composition of matter comprising a copper promoted,reduced and carbided iron-cobalt alloy, said composition beingsubstantially isostructural with Chi-Fe₅ C₂ (Hagg carbide), asdetermined by X-ray diffractometry, and possessing a BET surface area ofgreater than 5 m² /g, said composition produced by contacting theabove-described iron-cobalt alloy with a carbiding atmosphere. A relatedcomposition is also provided being isostructural with Fe₃ C (cementite)and having a BET surface greater than 5 m² /g.

Furthermore, there is provided a process for producing thecopper-promoted, iron-cobalt spinel composition described abovecomprising the steps of: (a) evaporating a liquid solution comprising amixture of iron and cobalt salts of at least one alpha-hydroxy aliphaticcarboxylic acid, wherein the molar ratio of total moles of said acid tototal moles of said iron and cobalt, taken as the free metals, is about1:1 or above, and wherein the atomic ratio of iron:cobalt, taken as thefree metals in said mixture is greater than 2 to 1; yielding anamorphous residue; and (b) calcining said residue at elevatedtemperature for a time sufficient to yield an iron-cobalt spinel,exhibiting a single phase spinel, isostructural with Fe₃ O₄ asdetermined by powder X-ray diffractometry followed by promotirng saidso-formed single phase spinel with copper and, if desired, additionalpromoter metal of Group IA or IIA or mixture thereof.

In addition, there is provided a process for preparing theabove-described, copper promoted, iron-cobalt alloy composition ofmatter comprising contacting the above-described copper promoted,iron-cobalt spinel with a reducing atmosphere under conditions ofelevated temperature, pressure and space velocity for a time sufficientto substantially reduce the metal oxides of the spinel.

There is also provided a process for preparing the above-describedcopper promoted reduced and carbided spinel comprising the step ofcontacting the above-described copper promoted iron-cobalt metal alloy,with a carbiding atmosphere under conditions of elevated temperature,pressure and space velocity for a time sufficient to substantiallycarbide said alloy.

There is further provided a process for synthesizing a hydrocarbonmixture containing C₂ -C₂₀ olefins comprising the step of contacting acatalyst composition, comprised of an unsupported, copper promoted, ironcobalt spinel, or mixture of said spinels which initially exhibit asingle spinel phase being isostructural with Fe₃ O₄, as determined byX-ray diffractometry, and possessing an initial BET surface area greaterthan 5 m² /g and an Fe:Co atomic ratio of 4:1 or above, said contactingconducted with a mixture of CO and hydrogen under conditions ofpressure, space velocity and elevated temperature for a time sufficientto produce said C₂ -C₂₀ olefins.

DESCRIPTION OF THE INVENTION AND PREFERRED EMBODIMENTS

The high surface area iron-cobalt spinels are isostructural with Fe₃ O₄,as determined by X-ray diffractometry using copper K alpha radiation andexhibit a single spinel phase. By the term "spinel" is meant a crystalstructure whose general stoichiometry corresponds to AB₂ O₄, where A andB can be the same or different cations. Included within this definitionis the commonly found spinel, Mg AL₂ O₄. A and B can have the followingcationic charge combinations: A=+2, B=+3, A=+4, B=+2, or A=+6, B=+1.Spinels contain an approximately cubic close-packed arrangement ofoxygen atoms with 1/8th of the available tetrahedral interstices and 1/2of the octahedral interstices filled, and can exhibit hundreds ofdifferent phases. Further description of the spinel structure can befound in "Structural Inorganic Chemistry" by A. F. Wells, Third Edition,Oxford Press, and the Article "Crystal Chemistry and Some MagneticProperties of Mixed Metal Oxides with the Spinel Structure" by G.Blasse, Phillips Research Review Supplement, Volume 3, pp 1-30, (1964).By the term "isostructural" is meant crystallizing in the same generalstructure type in that the arrangement of the atoms remains very similarwith only minor changes in unit cell constants, bond energies, andangles. By the term "single spinel phase" is meant one structural andcompositional formula, corresponding to a single spinel material intowhich all of the metal components are incorporated, and exhibiting onecharacteristic X-ray diffraction pattern.

These spinels possess a BET surface area greater than 5 m² /g asdetermined by the well-known BET surface area measurement technique asdescribed in reference JACS Vol. 60, p. 309 (1928) by S. Brunauer, P. H.Emmett, G. Teller, and preferably the spinel has a surface area greaterthan 50 m² /g and particularly preferred of about 100 to 300 m² /g. Thisobtained surface area is in contrast to conventional methods of spinelformation, e.g., high temperature sintering of component oxides in anoxygen-free atmosphere which results in surface areas generally in therange of about 0.1 to 1 m² /g. The high surface area obtained in thepresent process corresponds to about 0.01 to 0.002 microns in particlesize.

The iron to cobalt atomic ratio of the metals in the spinel is 4:1 orabove and is preferably in the range of 7:1 to 35:1, and particularlypreferred in the range of 19:1 to 20:1. The amount of copper promoteremployed will range from about 0.1 to 5 gram atom percent based on thecombined iron and cobalt content of the spinel preferably the amount ofcopper promoter will range from about 0.5 to 2 gram atom %. As set forthabove, the copper may be deposited on or added to the spinel byimpregnating the spinel with a solution of a suitable copper salt suchas copper nitrate, sulfate, halide, acetate, etc.

The spinel can be represented by the formula: Fe_(x) Co_(y) O₄, whereinx and y are decimal or integer values other than zero, and wherein thesum of x plus y is 3 and the ratio of x to y is 4:1 and preferably beingabout 7 to 1 to 35 to 1. Particularly preferred is where the iron tocobalt atomic ratio is about 19 to 20 to 1. Illustrative, butnon-limiting examples of spinels corresponding to the formula includeFe₂.85 Co₀.15 O₄, Fe₂.625 Co₀.375 O₄, Fe₂.97 Co₀.03 O₄, and Fe₂.25Co₀.75 O₄. The composition utilized may comprise a mixture of spinels inwhich at least two iron-cobalt spinels are present, being isostructuralwith Fe₃ O₄, having BET surface areas greater than 5 m² /g, wherein saidspinels individually possess different iron-cobalt atomic ratios, being4:1 or above.

Physical properties, in general, of these spinels are similar to thoseof magnetite, Fe₃ O₄, and include: melting point above 1400° and brownto black in color.

Additional promoter metal selected from the group consisting essentiallyof one or more metals of Group IA and IIA can also be used in thecatalyst composition to promote olefin formation in a Fischer-Tropschprocess. General classes of suitable promoter agents include carbonates,bicarbonates, organic acid salts, e.g. acetates, inorganic acid saltssuch as nitrates, halides, sulfates and hydroxides of the Group IA andIIA metals including lithium, sodium, potassium, rubidium, cesium,barium, calcium, strontium, magnesium, and the like. Illustrative, butnon-limiting examples of specific promoter agents include potassiumcarbonate, potassium sulfate, potassium bicarbonate, cesium chloride,rubidium nitrate, lithium acetate, potassium hydroxide, and the like.Preferred are the Group IA compounds potassium carbonate beingparticularly preferred. These promoters can be added to the iron-cobaltspinel, if desired, simply by impregnating the iron-cobalt spinelcomposition with an aqueous solution of one or more of said promoteragents and drying the resulting impregnate.

The additional promoter, if used, will generally be present in about a0.1 to 10 gram-atom % of metal ion based on the total, combined Fe-Cometals gram-atoms. A preferred level of promoter agent is in the rangeof 1 to 2 gram-atom %. A particularly preferred spinel composition ofthe subject invention is Fe₂.85 Co₀.15 O₄ /1% Cu, 2% K.

In the empirical formulas used herein, the amount of the promoter agent,e.g., potassium, is expressed in terms of gram atom percent based on thetotal gram-atoms of metals used. Thus, "1 gram-atom percent ofpotassium" signifies the presence of 1 gram-atom of potassium per 100total gram atoms of combined gram atoms of Fe and Co.

The copper-promoted spinels undergo unexpectedly facile in-situreduction in a slurry liquid and pretreatment to form copper-promotediron-cobalt alloys, which are further in situ carbided to form activeslurry catalysts in a Fischer-Tropsch slurry process for making C₂ -C₂₀olefins from CO/hydrogen.

The spinels can be made by a process in which an aqueous solution ofcobalt and iron salts of an alpha-hydroxy aliphatic carboxylic acid, isevaporated to dryness, leaving an amorphous residue, which is thenheated at elevated temperature to substantially form the spinel, as asingle spinel phase, being isostructural with Fe₃ O₄ and possessing asurface area greater than 5 m² /g, preferably above 50 m² /g. Theheating is conducted such that no significant loss in surface area ofthe final spinel is incurred.

The key to the synthesis of these spinels is in the use of an organic,saturated, aliphatic, alpha-hydroxy carboxylic acid to form a complexsalt, which is soluble in the aforementioned aqueous medium, at a pH onthe acidic side, i.e., pH of 5-7. The solubility of the iron and cobaltorganic salts of the alpha-hydroxy carboxylic acid preventcrystallization from occurring, resulting in a crystalline product beingobtained from the solution, which would possess a relatively low surfacearea.

This method of preparation utilizes an alpha-hydroxy aliphaticcarboxylic acid which acts as a solubilizing agent for the iron andcobalt salts in the aqueous solution. Any saturated aliphaticalphahydroxy carboxylic acid, containing at least one alpha-hydroxygrouping, can be used to form the soluble iron and cobalt salts in thesubject invention process in aqueous solution, is deemed to be includedwithin the scope of this invention. Representative examples of suchacids which can be mono-hydroxy or di-hydroxy or mono-carboxylic ordi-carboxylic are glycolic, malic, glyceric, mandelic, tartaric, lacticacids and mixtures thereof. A preferred carboxylic acid used in theprocess is glycolic acid.

The amount of acid used is at least the stoichiometric amount, i.e., 1to 1 molar ratio for each metal present and preferably in about a 5-10%molar excess of the stoichiometric amount. Higher ratios can be used, ifit is economical to do so. Lower amounts can also be used but wouldresult in incomplete iron and cobalt acid salt formation.

The first step in the process comprises forming an aqueous solution bydissolving iron salts and cobalt salts, in a water-soluble salt formsuch as their nitrates, sulfates, chlorides, acetates, and the like, inwater.

The concentration of the salts in the aqueous liquid is not critical tothe extent that the salts are present in less than a saturated solutionto avoid precipitation. For example, an 80-90% saturated solution, ofcombined dissolved metal molarities for avoiding precipitation in theprocess, can be effectively used.

The temperature of the aqueous solution is not critical and may be aboveroom temperature to aid in the solubilizing process. However, roomtemperature is adequate and is the temperature generally used in theprocess. The pressure also is not critical in the process andatmospheric pressure is generally used.

The aqueous solution can also contain a small amount of organic solventsuch as ethanol, acetone, and the like for aiding in the solubilizing ofthe iron and cobalt salts of the alpha-hydroxy carboxylic acid.

Following the dissolving of the iron and cobalt salts, the alpha-hydroxycarboxylic acid is added, together with a sufficient quantity of base,usually being ammonium hydroxide, sodium hydroxide, potassium hydroxide,and the like, preferably ammonium hydroxide, to solubilize the resultingacid salts. The amount of base added is sufficient to keep the pH in therange of about 5 to 7.0.

It should be noted that the exact sequence of steps need not be adheredto as described above, with the proviso that the resulting aqueoussolution contain dissolved iron and cobalt salts in stoichiometricamounts as iron and cobalt salts of alpha-hydroxy carboxylic acid insolution. If there are any insoluble materials present after addition ofthe base and organic acid, they should be filtered prior to theevaporation step.

At this point, the resulting solution is evaporated, as for example, byair drying, or under reduced pressure, at elevated temperature, aspracticed in a rotary evaporator, or in a vacuum drying oven.

The resulting material from the evaporation step is an amorphousresidue, generally being a powder. This residue is heated at elevatedtemperature at 100° to 600° C. for about 1 to 24 hours in generally airto result in a substantially single spinel phase which is isostructuralwith Fe₃ O₄, as determined by X-ray diffractometry, as previouslydescribed herein. Preferred temperature range is 100°-400° C., andparticularly preferred is about 350° C. for spinel formation.

A further subject of the instant invention is a composition of mattercomprising a copper promoted, reduced, iron-cobalt metallic alloy formedfrom the copper-promoted spinel described above, said alloy beingisostructural with alpha-iron, as determined by X-ray diffractometry,and preferably possessing a BET surface area of at least about 5 m² /gor higher.

Generally preferred is where the surface area is about 5-10 m² /g andparticularly preferred being 6-8 m² /g. The atomic ratio of iron tocobalt is not restricted and can be 4:1 and above. Generally, however,for C₂ -C₂₀ olefin synthesis in the subject process described herein,the iron-cobalt atomic ratio is preferably about 4 to 1 and above andmore preferably being about 7 to 1 to 35 to 1 and a particularlypreferred range is of about 19:1 to 20:1.

The copper-promoted iron-cobalt alloy can be produced by reducing theabove-described copper-promoted iron-cobalt spinel in a reducingatmosphere at elevated temperature generally of about 240° C. and aboveand preferably 300° to 400° C. The reduction can be carried out withvarious reducing gases including hydrogen, H₂ /CO, and the like, andmixtures thereof. Preferably hydrogen gas alone is generally used in aninert carrier medium such as helium, neon, argon, or nitrogen, in theabsence of CO when substantially pure, non-carbided alloy is desired.

The alloy can be prepared ex situ in a tube reactor or in situ in aFischer-Tropsch slurry process. The in situ preparation is conducted inthe slurry apparatus when the above described copper-promoted spinel isreduced while suspended in the slurry liquid, in a reducing atmospherebeing preferably a hydrogen atmosphere at elevated temperature beingabout 240° C., or above, preferably at 240°-300° C., at a spacevelocity, pressure, and hydrogen concentration sufficient to causesubstantial reduction of the spinel to the alloy. Substantial reductionis complete when the X-ray diffraction pattern shows a patternsubstantially isostructural with alpha-iron.

The above-described alloy is useful in forming a carbided,copper-promoted iron-cobalt catalyst useful in the subjectFischer-Tropsch slurry process for making C₂ -C₂₀ olefins, as describedherein. Also, subjects of the instant invention are compositions ofmatter being copper promoted, reduced and carbided iron-cobalt alloys,one being isostructural with Fe₅ C₂, "Hagg carbide" as described inTrans. of the Iron & Steel Inst. of Japan, Vol. 8, p. 265 (1968) byNagakura et al., as determined by X-ray diffractometry and possessing aBET surface area of greater than 5 m² /g; and two, being isostructuralwith Fe₃ C "cementite", as determined by X-ray diffractometry, andpossessing a BET surface area of greater than 5 m² /g.

Preferred is where the surface area of either material is about 25-200m² /g and particularly being preferred of about 60-150 m² /g. includingboth the formed Fe-Co carbide and surface carbon formed during thecarbiding step.

The atomic ratio of the iron:cobalt is not restricted for eithercomposition but generally for use in the subject process for producingC₂ -C₂₀ olefins is 4:1 or above and preferably 7:1 to 35:1 particularlypreferred in the range of about 19-20:1.

The copper promoted, carbided iron-cobalt alloy, having an X-raydiffraction pattern isostructural with Fe₅ C₂, can be produced bycarbiding the copper promoted iron-cobalt alloy, described hereinabove,in a suitable carbiding atmosphere at elevated temperature of up toabout 400° C. Temperatures above 500° lead to formation of Fe-Cocarbides which are isostructural with Fe₃ C, cementite.

Carbiding atmospheres which can be used to produce the subject reduced,carbided, catalyst include CO, CO/hydrogen, aliphatic hydrocarbons,aromatic hydrocarbons, and the like. A preferred carbiding atmosphere isCO/hydrogen. When using CO/hydrogen carbiding atmosphere, mixtures ofCO/hydrogen can be used in a 1:10 to 10:1 molar volume ratio. Apreferred ratio used for carbiding purposes is a 1:1 molar ratio.

The carbiding step is generally conducted at a temperature of about 250°C., or above and preferably at 300° to 400° C. A preferred method ofcarbiding the alloy is in situ in the slurry liquid to be used in theFischer-Tropsch process. A particularly preferred method is where thespinel is treated with a mixture of CO/hydrogen and reduced and carbidedin situ in one step prior to hydrocarbon synthesis. The pressure isgenerally about 1 atmosphere, and a space velocity of about 20-20,000v/v/hr is chosen in order to completely carbide the starting iron-cobaltoxide which can be determined by X-ray diffractometry when the materialbecomes isostructural with Haag carbide, Fe₅ C₂. The Haag-type Fe-Cocarbides produced in this process are of the general formula: Fe₅₋(5/3)yCo.sub.(5/3)y C₂, and also include surface carbon produced during thecarbiding process. Carbiding temperatures above 500° C. and preferably500°-700° C., lead to formation of a mixed Fe-Co carbide of the generalformula Fe_(3-y) Co_(y) C, which is generally formed under ex situprocedures which allow the use of higher temperatures than possible inthe in situ slurry process.

The resulting carbide is an active slurry catalyst for producing C₂ -C₂₀olefins in the described Fischer-Tropsch slurry process.

If the above-described alloy and carbide, are prepared ex-situ orindependently of the slurry apparatus, they may be pyrophoric andinconvenient to handle. In that case, the material may be passivated bycontact with oxygen for a sufficient time to reduce or eliminate thepyrophoric tendency. Generally, the oxygen used in the passivatingprocess is used in an inert gas stream carrier such as helium for asufficient time to cause passivation. Generally, this is conductedpreferably at room temperature, at a pressure and space velocity whichare convenient and easy to control and to maximize the efficiency of theprocess needed for complete passivation.

Also, a subject of the instant invention is a Fischer-Tropsch processfor producing C₂ -C₂₀ olefins by utilizing the copper promotediron-cobalt spinel, copper promoted iron-cobalt alloy and the reduced,carbided, copper promoted iron-cobalt spinel catalyst describedhereinabove.

Although a fixed bed process can be used, a preferred process mode foroperating the Fischer-Tropsch process utilizing the catalysts describedherein is a slurry-type process wherein the catalyst in fine particlesize and high surface area being above 5 m² /g is suspended in a liquidhydrocarbon and the CO/hydrogen mixture forced through the catalystslurry allowing good contact between the CO/hydrogen and the catalyst toinitiate and maintain the hydrocarbon synthesis process.

Advantages of a slurry process over that of a fixed bed process are thatthere is better control of the exothermic heat produced in theFischer-Tropsch process during the reaction and that better control overcatalyst activity maintainance by allowing continuous recycle, recovery,and rejuvenation procedures to be implemented. The slurry process can beoperated in a batch or in a continuous cycle, and in the continuouscycle, the entire slurry can be circulated in the system allowing forbetter control of the primary products residence time in the reactionzone.

The subject process can use any of the abovedescribed materials, ascatalyst or catalyst precursors: the copper promoted iron-cobalt spinelisostructural with Fe₃ O₄ ; the copper promoted iron-cobalt alloyisostructural with alpha-iron; or, the reduced, carbided, copperpromoted iron-cobalt alloy which is isostructural with Fe₅ C₂, or Fe₃ C.All the materials must have a BET surface area of greater than 5 m² /g,to be applicable in the efficient claimed slurry process describedherein. These materials can also be made independently of the apparatusprior to use or can be made in situ in the apparatus during the carryingout of the process. A preferred procedure is where the copper promotedspinel, in high surface area form is pretreated in situ in the slurryliquid, in either distinct reduction-carbiding steps or in onereduction-carbiding step as with CO/hydrogen at elevated temperature. Afull discussion of each of the materials, their properties and theirpreparation are given hereinabove and need not be reiterated.

The slurry liquid used in the process is a liquid at the reactiontemperature, must be chemically inert under the reaction conditions andmust be a relatively good solvent for CO/hydrogen and possess goodslurrying and dispersing properties for the finely divided catalyst.Representative classes of organic liquids which can be utilized are highboiling paraffins, aromatic hydrocarbons, ethers, amines, or mixturesthereof. The high boiling paraffins include C₁₀ -C₅₀ linear or branchedparaffinic hydrocarbons; the aromatic hydrocarbon include C₂ -C₂₀ singlering and multi- and fused ring aromatic hydrocarbons; the ethers includearomatic ethers and substituted aromatic ethers where the ether oxygenis sterically hindered from being hydrogenated; the amines include longchain amines which can be primary, secondary, and tertiary amines,wherein primary amines preferably contain at least a C₁₂ alkyl group inlength, secondary amines preferably contain at least two alkyl groupsbeing C₇ or greater in length, and tertiary amines preferably contain atleast three alkyl groups being C₆ or higher in length. The slurry liquidcan contain N and O in the molecular structure but not S, P, As or Sb,since these are poisons in the slurry process. Representative examplesof specific liquid slurry solvents useful are dodecane, tetradecane,hexadecane, octadecane, cosane, tetracosane, octacosane, dotriacontane,hexatriacontane, tetracontane, tetratetracontane, toluene, o-, m-, andp-xylene, mesitylene, C₁ -C₁₂ mono- and multi-alkyl substitutedbenzenes, dodecylbenzene, naphthalene, anthracene, biphenyl,diphenylether, dodecylamine, dinonylamine, trioctylamine, and the like.Preferred liquid hydrocarbon slurry solvent is octacosane or hexadecane.

The amount of catalyst used in the liquid hydrocarbon slurry solvent isgenerally about 10 to 60 g. of dry catalyst per 500 g. slurry liquid.Preferably about 30 to 50 g. dry catalyst per 500 g. slurry liquidslurry is utilized, being in about a respective 5:1 to 10:1 weightratio.

The slurry system, comprised of the slurry liquid and finally dividedcatalyst, is generally stirred to promote good dispersion during thepretreatment in the process to avoid catalyst settling and to eliminatemass transport limitations between the gas and liquid phases. In atypical laboratory unit the rate of stirring is generally carried out inthe range of about 600 to 1,200 rpm and preferably 1,000 to 1,200 rpm.

Prior to the CO/hydrogen hydrocarbon synthesis run, the reduced andcarbided, copper promoted iron-cobalt catalyst is generally conditionedin the apparatus by purging with nitrogen to remove reactiveoxygen-containing gases and then the temperature is increased whilestirring to the reaction temperature range. Then the system is generallysubjected to a hydrogen treatment for a sufficient time to insurecomplete removal of any surface metal oxide present which wouldinterfere in hydrocarbon synthesis.

Optionally, and preferably if the catalyst is prepared in situ, then thehydrogen treatment is generally not required or is only practiced for ashort period of time. The pressure and space velocity during the inertgas-hydrogen conditioning step are not critical and can be utilized inthe range which is actually used during actual hydrocarbon synthesis.

Following the conditioning step, the CO/hydrogen feedstream isintroduced into the slurry catalyst chamber and the pressure, spacevelocity, temperature, and hydrogen/CO molar ratio is then adjusted, asdesired, for hydrocarbon synthesis conditions.

In the process, the hydrogen and CO are used in a molar ratio in thegaseous feedstream in about a 10:1 to 1:10 molar ratio, preferably 3:1to 0.5:1, and particularly preferred 1:1 to 2:1 molar ratio.

The temperature in the process is generally in the range of about 200°to 300° C., preferably being 230° to 270° C., and particularly preferredof about 240°-260° C. Higher temperature ranges can also be used buttend to lead to lighter products and more methane, lower temperatureranges can also be used but tend to lead to lower activity and waxformation.

The pressure useful in the process is generally conducted in the rangeof about 50 to 400 psig and preferably about 70 to 225 psig. Higherpressures can also be used but tend to lead to waxy materialsparticularly in combination with lower temperature.

The space velocity used in the process is generally about 100 to 4,000volumes of gaseous feedstream/per volume of dry catalyst in theslurry/per hour and is preferably in the range of about 400 to 1,200v/v/hr, and particularly preferred of 800-1,200 v/v/hr. Higher spacevelocities can also be used but tend to lead to lower % CO conversion,and lower space velocities can also be used but tend to lead to moreparaffinic products.

Generally, after the pretreatment, the CO/hydrogen feedstream isintroduced to initiate and maintain hydrocarbon synthesis.

The percent CO conversion obtainable in the subject process, whileproviding substantial quantities of C₂ -C₂₀ olefins, will generallyrange from about 30 to 80 percent and usually from about 50 to 60percent for sufficient C₂ -C₂₀ olefin production.

"Total hydrocarbons" produced in the process is related to theselectivity of percent CO conversion to hydrocarbons being thosehydrocarbons from C₁ to about C₄₀ inclusive. Total hydrocarbonselectivity is generally 0 to 50 percent and higher, of the total COconverted, and the remainder converted to CO₂.

The percent C₂ -C₂₀ hydrocarbons of the total hydrocarbons producedincluding methane and above is about 60 to 90 wt. %. The percent of C₂-C₂₀ olefins produced, of the C₂ -C₂₀ total hydrocarbons produced isabout 60 to 70 wt. %. The olefins produced in the process aresubstantially alpha olefins.

The selectivity to methane based on the amount of CO conversion is about1 to 10 weight percent of total hydrocarbons, produced. Preferably about5 percent, and lower, methane is produced in the process.

As discussed above, the percent selectivity to CO₂ formation in theprocess is about 10 to 50 percent of CO converted.

Preferably, the reaction process variables are adjusted to minimize CO₂production, minimize methane production, maximize percent CO conversion,and maximize percent C₂ -C₂₀ olefin selectivity, while achievingactivity maintenance in the catalyst system.

Generally, this format can be derived in a preferred mode of operatingthe process where the slurry liquid used is hexadecane, the catalystused is Fe₂.85 Co₀.15 O₄ /1% Cu, 2% K, the catalyst/liquid weight ratiois 40/500, the system is stirred at 1,200 rpm, and pretreatmentprocedure is conducted in situ in a one step procedure using 9:1 H₂ /N₂at 220° C., atmospheric pressure, 1200 v/v/hr. space velocity, for aperiod of 5 hrs., and the process conducted at the hydrogen:CO molarratio is 1:1, the temperature is conducted at about 245° C., at apressure of 7-150 psig, and space velocity 1,000-1200 v/v/hr. Bycarrying out the above process in the stated variable ranges efficientactivity maintenance and production of C₂ -C₂₀ olefins can be achieved.

The effluent gases in the process exiting from the reactor may berecycled if desired to the reactor for further CO hydrocarbon synthesis.

Methods for collecting the products in the process are known in the artand include fractional distillation, and the like. Methods for analyzingthe product liquid hydrocarbons and gaseous streams are also known inthe art and generally include gas chromatography, liquid chromatography,high pressure liquid chromatography and the like.

Apparatus useful in the preferred process is any conventionalslurry-type reactor, being horizontal or vertical, being stationary orcyclical, in catalyst slurry. Other apparatus not specifically describedherein will be obvious to one skilled in the art from a reading of thisdisclosure.

The invention will be more readily understood by reference to theexamples below.

EXAMPLES

Unless otherwise indicated, the selectivity weight percentages ofproduct hydrocarbons is given on a CO₂ -free basis.

EXAMPLE 1 Preparation of Fe₂.85 Co₀.15 O₄ Spinel

198.04 grams of ferric nitrate in 144 water and 7.5 grams of cobaltnitrate in 8 cc of water were mixed together. To this solution was addeda solution of 41.6 grams of 85% glycolic acid containing 45 cc ofammonium hydroxide such that the resulting pH of the ammonium glycolatesolution was about 6.5. The ammonium glycolate solution constituted 0.51moles of glycolic acid such that about a one to one molar ratio of totalmetals including iron and cobalt to glycolic acid resulted. The ammoniumglycolate solution was added to the aqueous solution containing iron andcobalt salts and the contents stirred. The resulting solution wasallowed to evaporate by air drying. Upon drying at room temperature theresulting solid was shown by X-ray diffraction to be an amorphousmaterial because of lack of sharp discrete reflections. The solid washeated in air at 350° C. for 2 hours. An X-ray diffraction pattern ofthe resulting material showed it to be a single phase cobalt-iron spinelisomorphous with Fe₃ O₄. The X-ray diffraction peaks were broadenedrelative to a compositionally equivalent material obtained by a hightemperature procedure. This indicated that the resulting obtainedmaterial was of very small particle size.

A number of different batches of this spinel were prepared using theprocedure set forth above. In all cases, the surface area of theresulting material ranged from about 80 to 200 square meters per gram.

Preparation of Fe₃ O₄

For comparative purposes, Fe₃ O₄ was prepared from ferric nitrate,glycolic acid and ammonium hydroxide using the procedure set forth abovefor the Fe₂.85 Co₀.15 O₄ spinel, except that no cobalt salt wasemployed.

Impregnation With Promoter

Samples of the spinel and Fe₃ O₄ prepared as set forth above wereimpregnated with either potassium or a mixture of potassium and copper.For the copper impregnation, an aqueous solution of cupric nitratehexahydrate was used in an amount sufficient to deposit one gram atom %of Cu on the spinel, based on the combined Fe and Co content. Theresulting copper impregnate was then dried in air for about two hours at125° C.

Following the Cu impregnation, samples of the dried impregnate werefurther impregnated with one gram atomic percent of potassium using anaqueous solution of potassium carbonate followed by drying of theresulting impregnated sample at 125° C. Some samples were impregnatedonly with K. The resulting solids had an empirical formula of eitherFe₂.85 Co₀.15 O₄ /1% K. or Fe₂.85 Co₀.15 O₄ /1% K., 1% Cu.

Preparation of Carbide Ex-Situ

In those cases where the catalyst was prepared ex-situ, the promotediron or iron-cobalt spinel was treated at 400° C. in a stream of 40volume percent hydrogen/40% helium/20% CO at 200 V/V/hr. for twentyfourhours. Following this, the sample was cooled to room temperature and1.0% oxygen in helium was introduced for one hour to passivate thematerial. The X-ray diffraction pattern of the resulting material wasisostructural with Fe₅ C₂. The BET nitrogen surface area of the materialwas at least about 150 m² /g. Analysis showed that about 40-50 weightpercent of the material was carbon and thus the material was a compositeof Fe_(5-x) Co_(xC2) /2 gram-atom % K., and, in some cases, 1% Cu andsurface carbon. In this case, x=O or 0.25.

Catalyst Runs

Into a slurry reactor, being a 300 cc Parr CSTR (continuous stirred tankreactor) was charged: 50 g of octacosane and 8.0 of either the ex-situcarbided catalyst or the Cu and/or K. promoted Fe or Fe-Co spinelprepared as set forth above. In those cases where the reactor wascharged with a promoted spinel that had not been carbided ex-situ, thecatalyst was formed in-situ in the reactor.

After a sample of catalyt or promoted spinel catalyst precursor wasloaded into the reactor, the system was purged with nitrogen and thenplaced under CO hydrogenation reaction conditions by adjusting thereaction temperature to 270° C., the H₂ /CO volume ratio to 2/1, thespace velocity to 2,000 V gaseous feed-stream/V dry catalyst/hr, thepressure to 75 psig, and the slurry stirrer speed to 600 rpm in theoctacosane solvent.

The actual gas flow rate through the reactor was 120/60/20 cc per min.of H₂ /CO/N₂. The effluent gas from the reactor was monitored by anHP-5840A Refinery Gas Analyzer to determine percent CO conversion andthe nature of the hydrocarbon products.

The results are set forth in Tables 1 and 2 below. In all cases, thevalues reported were determined after the catalyst had been on-stream inthe reactor for a period of at least 16 hours.

Referring to the Tables, Table 1 sets forth the results of threedifferent catalysts formed in-situ in the reactor from the promoted Feor Fe/Co spinel. The results show the high selectivity of α-olefinproduction achieved by the copper promoted catalyst of this inventioncompared to a similar catalyst which was not promoted with copper. Thedata for the Fe spinel merely serves as a comparison for conventionaliron catalysts. Table 2 compares the result obtained using a catalyst ofthis invention prepared both in-situ and ex-situ. These data illustratethat the catalysts of this invention are preferably prepared in-situ forgreatest alpha olefin selectivity.

                  TABLE I                                                         ______________________________________                                        Catalysts Prepared In-Situ in The Reactor                                               Fe.sub.3 O.sub.4 /                                                                  Fe.sub.2.85 Co.sub.0.15 O.sub.4 /                                                         Fe.sub.2.85 Co.sub..15 O.sub.4 /                            2% K.sup.a                                                                          2% K        2% K/1% Cu                                        ______________________________________                                        % CO conversion                                                                           67      77          86                                            % CH.sub.4 make                                                                           2.02    4.4         4.2                                           % olefins in C.sub.2 -C.sub.4                                                             47.5    91          87                                            hydrocarbon                                                                   fraction                                                                      C.sub.10 distribution                                                         olefins             49.0        59                                            n - paraffins       14.9        15                                            alcohols            1.0         3                                             olefins             4.1         2                                             All Else            31          21                                            ______________________________________                                         Note:                                                                         .sup.a No measurable amount of C.sub.10 's produced with this catalyst.  

                  TABLE 2                                                         ______________________________________                                        Catalysts Prepared In-Situ and Ex-Situ                                                 Fe.sub.3 O.sub.4/                                                                    Fe.sub.2.85 Co.sub..15 O.sub.4/                                                           Fe.sub.2.85 CO.sub..15 O.sub.4 /                           2% K   1% CU, 2% K 1% Cu, 2% K                                                ex-situ                                                                              ex-situ     in-situ                                           ______________________________________                                        % CO conversion                                                                          49       54          86                                            % CH.sub.4 make                                                                          3.8      4.5         4.2                                           % olefins  77       85          87                                            produced in                                                                   C.sub.2 -C.sub.4 hydro-                                                       carbon fraction                                                               C.sub.10 distribution                                                         olefins    50       46          59                                            olefins    8        6.0         2                                             alcohols   2        1           3                                             n - paraffins                                                                            17       18          15                                            All Else   23       29          21                                            ______________________________________                                    

We claim:
 1. A composition of matter comprising a reduced and carbided,copper promoted iron-cobalt alloy, said composition being substantiallyisostructural with chi-Fe₅ C₂, as determined by X-ray diffractometry andpossessing a BET surface area of greater than 5 m² g, said compositionproduced by contacting, with a carbiding atmosphere for a timesufficient to produce said composition, said copper-promoted ironcobaltalloy, being isostructural with metallic alpha iron as determined bypowder X-ray diffractometry, possessing a BET surface area of greaterthan 5 m² /g, wherein said alloy was produced by contacting, with areducing atomosphere, an unsupported Group IA or IIA metal salt promotediron-cobalt spinel, or mixture thereof, said spinel exhibiting a singlephase powder x-ray diffraction pattern substantially isostructural withFe₃ O₄, and possessing a BET surface area greater than 5 m² /g and aniron-cobalt atomic ratio of 4 to 1 or above.
 2. The composition ofmatter of claim 1 wherein said surface area ranges from about 25 to 200m² /g.
 3. The composition of matter of claim 2 wherein said surface areais about 60-150 m² /g.
 4. The composition of matter of claim 1 whereinsaid copper is present in an amount of from about 0.1 to 5 gram atom %based on the total Fe-Co content of said alloy.
 5. The composition ofmatter of claim 4 wherein said iron-cobalt atomic ratio is in the rangeof about 7:1 to 35:1.
 6. The composition of matter of claim 5 whereinsaid iron-cobalt atomic ratio is about 19-20:1.
 7. The composition ofmatter of claim 6 wherein said iron-cobalt atomic ratio is about 19:1.8. A composition of matter comprising a reduced and carbided, copperpromoted iron-cobalt alloy, said composition being isostructural withFe₃ C, as determined by powder X-ray diffractometry, and possessing aBET surface area of greater than 5 m² /g.
 9. A process for producing acomposition of matter comprising an unsupported, copper promotediron-cobalt spinel or mixture thereof, said spinel exhibiting a singlephase powder X-ray diffraction pattern substantially isostructural withFe₃ O₄, and possessing a BET surface area greater than 5 m² /g and aniron-cobalt atomic ratio of 4 to 1 or above, comprising the steps of (a)evaporating a liquid solution comprising a mixture of iron and cobaltsalt of at least one alpha-hydroxy aliphatic carboxylic acid, whereinthe molar ratio of total moles of said acid to total moles of said ironand cobalt, taken as free metals, is about 1:1, or above, and whereinthe atomic ratio of iron:cobalt, taken as the free metals in saidmixture, is greater than 2 to 1, yielding an amorphous residue; (b)calcining said residue at elevated temperature for a time sufficient toyield an iron-cobalt spinel exhibiting at least one spinel phaseisostructural with Fe₃ O₄, as determined by powder X-ray diffractometry;and (c) impregnating the composition of (b) with a solution of coppersalt, followed by drying the resulting impregnate.
 10. The process ofclaim 9 wherein said acid is selected from glycolic, malic, tartaric, orlactic acids, or mixtures thereof.
 11. The process of claim 10 whereinsaid acid solution is an aqueous solution.
 12. The process of claim 11wherein the pH of said solution is 5 to 7.0.
 13. The process of claim 12wherein said acid is glycolic acid.
 14. A composition of mattercomprising the amorphous residue produced by the process in step (c) ofclaim
 9. 15. A process for preparing a reduced, carbided, copperpromoted iron-cobalt alloy composition comprising a reduced and carbidedcopper promoted iron-cobalt alloy which is substantially isostructuralwith chi-Fe₅ C₂, as determined by powder X-ray diffractometry andpossessing a BET surface area of about 25-200 m² /g, said processcomprising contacting a reduced iron-cobalt metal alloy beingisostructural with metallic alpha iron, as determined by powder X-raydiffractometry, and possessing a BET surface area of greater than 5 m²/g, with a carbiding atmosphere under conditions of elevatedtemperature, pressure and space velocity, for a time sufficient tosubstantially carbide said alloy.
 16. The process of claim 15 whereinsaid carbiding atmosphere comprises CO and H₂.
 17. The process of claim15 wherein said process is carried out at a temperature of about 250° C.or above.
 18. A process for preparing a reduced, carbided, copperpromoted iron-cobalt alloy composition comprising a reduced and carbidedcopper promoted iron-cobalt alloy which is substantially isostructuralwith chi-Fe₅ C₂, as determined by X-ray diffractometry and possessing aBET surface area of about 25-200 m² /g comprising the steps of (a)contacting an unsupported, copper metal salt promoted iron-cobaltspinel, or mixture thereof, said spinel exhibiting a single spinel phaseisostructural with Fe₃ O₄, and having a BET surface area greater than 5m² /g and an iron-cobalt atomic ratio of 4:1 or above, suspended in aFischer-Tropsch slurry liquid, with a reducing atmosphere underconditions of elevated temperature, pressure and space velocity, for atime sufficient to substantially reduce the metal oxides of the spinel;and (b) contacting said spinel, concurrently or subsequent to step (a),with a carbiding atmosphere under conditions of elevated temperature,pressure, and space velocity, for a time sufficient to substantiallycarbide said alloy.
 19. A composition of matter comprising the reducedcarbided, copper promoted iron-cobalt alloy suspended in aFischer-Tropsch slurry liquid produced by the process of claim 18.